Kuka KR C4 Operating Instructions

The axis is experiencing an overload, indicated by the mean continuous current being too high or excessive power consumption. This can be caused by an excessive load in the robot program, recent machine modifications, or adverse temperature influences on the system.

An overcurrent condition has occurred in the power unit, specifically indicating a ground fault. This suggests an insulation breakdown or a short circuit to ground within the motor or its associated cabling, posing a safety risk.

A fault has briefly resulted in an overcurrent that exceeds the maximum current rating of the KPP, such as a short-circuit. This indicates an immediate and severe current surge within the motor circuit, potentially causing component damage.

An overvoltage condition has occurred in the intermediate DC circuit during operation. This can be caused by high incoming mains voltage, a fault in the ballast switch, or excessive braking energy being fed back into the DC bus.

An undervoltage condition has occurred in the intermediate DC circuit during operation. This can be caused by low incoming mains voltage, issues with the intermediate circuit cabling, or a fault in the KPP/KSP charging circuit that prevents proper voltage build-up.

The KPP or KSP device has detected an internal hardware fault. This indicates a critical issue within the device's internal electronics that requires direct attention to the component itself.

One or more mains phases supplying the KPP/KSP device have failed. This suggests an issue with the incoming AC power supply to the drive, potentially leading to incorrect operation or shutdown.

The supply voltage for the KPP/KSP device has fallen below 300 V. This indicates an undervoltage condition on the power supply to the drive, which can prevent proper operation or lead to protective shutdown.

An overvoltage condition occurred in the KPP/KSP during the charging phase of the intermediate circuit. This could be due to excessively high incoming mains voltage or an insufficient number of capacitors connected to the system for proper voltage regulation.

The KPP has detected an error within the ballast circuit, which includes the brake resistor. This indicates a problem with the energy dissipation system responsible for braking the motor, potentially leading to uncontrolled deceleration.

The braking energy in the ballast circuit is permanently too high. This often results from frequent or heavy braking operations that exceed the continuous power rating or capacity of the brake resistor, leading to potential overheating.

The KPP/KSP device has detected an internal error. This indicates a problem within the device's internal electronics or firmware that cannot be resolved externally without component replacement.

An overtemperature condition has been detected within the KPP or KSP device for a specific axis. This indicates that the internal operating temperature of the drive or control unit has exceeded its safe limits, potentially due to insufficient cooling or excessive load. Continued operation in this state can lead to component damage or premature failure.

An overtemperature condition has been detected specifically on the heat sink of the KPP or KSP device for a specific axis. This indicates that the component responsible for dissipating heat from the power electronics is not functioning effectively, leading to elevated temperatures. Persistent high heat sink temperatures can degrade component performance and longevity.

A failure has been detected in one or more motor phases supplied by the KPP or KSP device for a specific axis. This typically indicates an open circuit, short circuit, or significant imbalance in the electrical connection between the drive and the motor. This condition prevents proper motor operation and can cause mechanical or electrical stress.

A communication error has occurred on the controller bus, specifically identified as an EtherCat issue, involving the KPP or KSP device for a specific axis. This indicates a disruption in data exchange between the KPP/KSP and the main controller or other bus participants. Loss of communication can prevent axis control and coordinated motion.

The KPP or KSP device for a specific axis has received an unknown status flag, indicating a software error within the EtherCat master. This suggests an issue with the EtherCat communication protocol or data interpretation on the master controller side. It can lead to unpredictable behavior or loss of control for the affected axis.

The KPP or KSP device for a specific axis is reporting an unknown internal device status. This indicates that the device is in an unidentifiable operational state, which could be due to an internal malfunction or a software anomaly. This condition may prevent proper operation and requires further investigation.

The KPP or KSP device for a specific axis has detected an internal hardware fault. This indicates a physical component failure within the unit itself, such as a faulty power supply component, damaged control board, or other internal defect. This fault typically renders the device inoperable.

A failure has been detected in one or more mains input phases supplying the KPP or KSP device for a specific axis. This indicates an issue with the incoming AC power supply to the drive, such as a blown fuse, tripped breaker, or open phase. Loss of a mains phase can cause imbalances, overheating, and prevent the drive from operating.

The charging process for the intermediate DC circuit has failed. This indicates an issue preventing the DC bus from reaching its operational voltage during start-up or after a power cycle, affecting drive readiness.

The brake cable monitoring device has signaled a fault, such as a short-circuit, overcurrent, or a break in the connection, affecting the collective brake. This indicates an issue with the brake control or wiring impacting multiple axes simultaneously.